., . . . . .. . mY".
qtfa~;~doperating cost is
. •. . '. ;tile essentialrequirem~ntwhen desjgnip.g the. discharge
.... , piping for a' pump.' This: contrasts with the need for
..re\iableope~tion when sizing the suction piping.
..IHhe ' . ugal pump receives saturated liquid on the
suction the liquid. becomes well subcooled in the
. ' . discharge me,; due to the increased pressure. This is one
, ..';. reason why filtbrs,.orifice rUns, ./ron9'ol valves, exchangers,
'a!'ld other flow'res~rietorsat:epl~d on the discharge side
, of process :pumps.;,., :""" .,;., ' The total head repre.sents a differential pressure ofP
',fn this article, we Will analyze and compute the resist-
."ances to flow on the discharge side of the process pump.
'. :"',As a rule, we 'can readily select economical sizes for
•',•.'.. discharge pipe ,up to about 12-in dill,. For larger diame-
" iers;we must often make 'it more-detailed cost compari-
, . Son, in order 'to ,choose between alternative discharge-
pipe des' ' . , J ' , .. '
"
By reviewing typical pump dala and' knowing only the
flo""rate,we can readilyindicate a reasonable design for
the •. hydraUlic. system," regardless of discharge-pressure
requitementsof the pumped liqui~.
PerformanceCurves-'-ln Fig.l;wefind a composite
rating '. chart' for a •. series Or standard chemical-process
pumps; and the head-capacity curve for a specific pump.
The performance curves for this pump show that it is
suitable for h~ndling flmvs frmn150 to 300 gpm (close
CHEMICAL ENGlNl:ERfNG1MAY 26. 1Q7S
Flow, gpm • . . . . . . .
Impeller diameter, in ..
Power,hp.. , , .. '.' :.>;.. 3 to 10
Efficiency, % ." , ,...•:...,58 to-67
Total head, ft water. " . . . . . . . . . • . . . 3()to 9(j
Fi~.lbfo;thf
All these data were obtained from
having a 4-in suction nozzle and a3-in discharge nozzle.
to 39 psi (when pumping water) between sllction and
discharge flanges.
For a flow of about 250 gpm, the suction-pipe size can
be 6 in, the discharge pipe 4in.The orifice run can be .
4 or 6 in, the control-valve size 3 or 4 in; block valves
and strainer should be line size. With these data, detailed
calculations can be made, pump total-head requirement
determined, .and impeller. diameter and motor size se-
lected.
A centrifugal· pump is adynamic. machine that can
perform only on points on the head-capacity curve. Con-
sequently,the sum of piping and components resistances
during operation must fall exactly on the head-capacity
curve. The relationship between the pump's head-
capacity curve and pipe-system resistance is shown in
Fig. 2. Resistance of the throttling valve sh?uldnot be
included as part of the' system resistance. Tii(;'gap be-
tween the head-capacity curve and the system-resistance
curve is available for throttling resistance (i.e., control-
valve;),.P). While pipe resistanceincreasfis with higher
flowrate, throttling resistance decreases. Or, at higher
113
CE I:lEFRESHER •..
PERFORMANCE of a typical series of centrifugal pumps
and detailed characteristics of the selected pump-Fig. 1
flowrates, the throttling valve has to open and pass larger
flows with less resistance.
In manufacturers' head-capacity curves, the "Total
Head" usually does not include velocity-head differences
calculated between suction and discharge flanges. Those
diagrams that include velocity-head differences indicate
"Total Dynamic Head" on the vertical scale. In this case,
velocity-head differences should be added to the total-
head calculations.
In a great number of publications, the head-capacity
114
...
The curves in this drawing suggest that when the dis-
charge is throttled, the system-resistance curve moves to
another position. Not so! Only one system-resistance
curve exists for a given discharge line.' The. varying.M'
of the control valve brings the system resistance up to
a point on the head-capacity curve.
Head-capacity curves are. drawn for. pumping water.
However, a centrifugal pump with a given impeller,
speed and size will develop the same head in feet, no
matter what the liquid or specific gravity-providing
viscosities are normal. Tile static-head pressure at the
pump nozzles will be. higher with a h~avier liquid, an4
the horsepower requirement will also increase. Brake-
horsepower requirements for pu1tlpingwaterar~ super"
imposed on the head-capacity curye(seeFig.lb). We
multiply the horsepower reqpired top~mp ~aterby .the
specific gravity of the liquid being pumped to obtain
.actual . • brake. horsep?wer,. Efficiency Cllrves are •. . . also
superimposed on ,the head-capt;lcityCUt'Yes(Fig.lb). The
ideal, normal. operatitlgpoi11tisitt.}h~m~um em-
. ciency range' JJ ' •••.. " ' i " « :
When calculating total-head require1l.1,ents atalterna-
live capacities, it is useful to know the operating points
 CE REFRESHER . ..

where Q, Hand E are capacity, total head, andefficiency,.

respectively, and wheresubscriptw stands for water, and
subscript vis stands for viscous liquid.
TwocPhase Flow-If the pressure drops below the
vapor pressure of the liquid inllie discharge tine (for
example, after a heat exchanger. ora control valve),
vaporization will occur. Friction resistance in the pipe
increases considerably. with the increased vapor content
of the liquid. This section of the discharge pipe should
be calculated for two-phase flow: If two-phase flow is
. expected in a pipeline between two pieces of process
. equipment, capital cost and operating cost can be re-
duced by locating this equipment side by side. Generally,
lines with two-phase flow should be short.

Total-Head Calculations

We can use the data plotted in Fig. 4 for selecting a

suitable size for the dischargepiping·of a·· centrifugal
pump. The shaded zones. in Fig. 4 will help in selecting
economical sizes for alloy or carbon-steel piping in the
on the head-capacity curve, so that the available con- case of electric-motor or stearn-turbine drives.· ...........•
trol-valve pressure differentials can be more closely esti- In general, economical sizes for discharge pipes can ..
mated. be easily recognized if we list the unit losses for several
If a pump has not been selected, we can still estimate adjacent pipe sizes. For example, the unit losses in .a
the increase in total head for a given pump when capacity Schedule 40 pipe for a 300-gprnflow, as obtained frorn
decreases by X% from a given capacity.. This increase in Fig. 4, yield: .
total head can range fromO.S to 1.0 multiplied by X%.
A high value for this increase (selected from the range
• 0.5 to 1.0), say 0.85X%, is justified for three reasons:
1. The pump will notbe undersized.
2. The head-capacity curve fof· a worn impeller will
have a more pronounced decline with increasing flow as
compared with a new impeller. In this case, the 4-in size isr~asonable for tlledis-
3. A somewhat increased control-valve ;j,P will provide charge pipe. The unit loss of a 3-in pipe will, rnost prob-
a more desirable plug position· at a maximum flow. ably, increase utility cost to an extent that cannot be
Viscous Flow-Areduction in head, capacity and effi- compensated for by lower capital <:ost8 of the pipeline
ciency, and an increase in horsepower,will occur when and components. And the cost of a possibly larger purnp
pumping viscous liquids instead of water. (NPSH re- and motor has not been taken into account. The unit loss
quirement does not change.) Fig. 3 shows a perform- of a 6-in pipe is far too lowfor an average process purnp.
ance~correction chart for conventional, single-stage, cen- Where the discharge line is very long, a· 6-in line rnight
trifugal pumps handling viscous Newtonian liquids for be reasonable, such as thecopting-water supply header
capacities between 10 to 100 gpm. A similar chart is to a distant point. . . .. . . ... .. ....•..
available for 100 to 1,000 gpmin the "Hydraulic Institute An example will best illustrate theconceptsJ()r calcu-
Standards" [1]. lating the pump's differential pressure: ... . . ..
These charts should not beused for multiple-impeller, .. A pump moves a liquid having a density, p, of 50 lb/ft3
mixed-flow and axial-flow pumps, or for pumps with from an overhead drurn loan elevated point 00 a col-
special hydraulic design. Manufacturers can supply vis- umn,'assketched here:
cosity~correction charts for their pumps.
To use Fig. 3, we select a pump from the' manufac-
turer's head-capacity curves at optimum efficiency, and
note the head,capacity and efficiency. We enter Fig. 3
with the same capacity..We intersect the head line, in
feet, and move horizontally left or right to viscosity; then
vertically up to intersect the· efficiency-correction factor,
CE,capacity-correction factor, CQ , and head-correction
factor, Cn. An example isdrawn in Fig. 3:
The corrected performance characteristics for viscous
flow will be: .
Qw X CQ = Qvis
Hw X Co = Hvis
E w xCE = Evis

116 MAY26,1.915fCHEMICALf:NGINEERING
UNIT ,pressure losses In new, commercial-steel pipe help in selecting suitable sizes for discharge piping-Fig. 4

Pressurein the drum, 1'1' is lOpsi,and pressure in components resistances vary with flowrate (see Fig. 2).
the column, P2 ,is 15 psi. Pressure drop across the control The analysis, therefore, becomes:
valve, APw , equals S psi; and the friction losses in the
suction and discharge lines are Apl == I psi and Ap'i = Suction,
Psi
Discharge,
Psi
9 psi, respectively. Let us calculate the required total
head for the pump, i.e., the differential pressure, !:J.P,
Vessel pressure PI = 10 P2 = 15

between the suction and discharge flanges.

Static-head pressure PHI = 5 Pm = 10
Friction loss /),PI = .::i /),P2 =-.2.
Both suction head and discharge head consist of four Total 14 34
components: static head, pressure head, velocity head,
and piping and. components resistance. Velocity-head We now subtract the total suction resistance from the
differences normally do nOt have to be calculated because discharge line backpressure totind the· pump's differ-
they are taken into account by U.S. pump manufacturers ential pressure excluding the control valve: 34 - 14 20 =
in their published. head-capacity curves. Pressure and psi. Choosing a control~valve !:J.Pcv of 5 psi, we must add
static head in Ii systemusuaIly remain constant with this to the pump's differential pressure of20 psi to obtain
changing capacities.. Suction-pipe, discharge-pipe and the total differential pressure across the pump flanges as
CHEMICAL ENGINEERINGlMAY 26, 1975 117
tE REFRESHER . ..

25 psi, or expressed ashead of liquid (the required total

head):
H = (25)(144)/50 = 72 ft

Example Illustrates Detailed Design ...

A centrifugal pump having a 4-insuction nozzle and
a 3-in discharge nozzle will handle a gas oil at a normal
flowrate of 250gpm through a piping and components
system, as d.rawnin Fig. 5. Allowing for a safety factor
of l.l, we' find that the maximum flowrate will be
, .- ~'.

1.l(250) = 275 gpm.Specific gravity and density are:

S60 = 1.18" and P60== 73.6 Ib/ft 3, respectively. At the We then find. the eqUivalent length for the suction line
flowing temperature o[555°F,S =1.04 andp= 64.87 and its fittings from j:!ata in Part 2 ()f this series (Chern.
Ib/ft 3.. Viscosity of the gas oil is O.Gep. There isa flow Eng., Jan. 6, 1975, Tables I to IV): '
control valve in the discharge line. Pipe length . .
Letus calculate the total head on the pump whenit 5 Short-radius elbows .;.: ~ . : •.. '. . . 75 ft
is expected to operate ata normal flowrate and at' a I Reducer .;'. ; .. ;.. .; . . .. .:; . ~ . .. 4 ft
maximumflowrate. 1 Strainer .. ... i •.;' . .; . . . . .-::, . . . • , . . '. 30 ft
We will begin the analysis by first determining the loss 1 Gate valve . •. ;. .' : .:.... . . 6.5 ft
in the suction .line and then that in the discharge line. 1 Inlet to pipe.·.·: .: •. ~:.:.~.. . 18 ft
.Pertinent data for the Schedule 40 pipe are: Total equivalent length, .L, : ...:. . . . . 172.5 ft

Suction Line Discharge Line Hence, the overallioss for the line and its fittings at
Nominal size,.in 6 4 the normal flow of 250 gpm becomes;·
I:l.Pl00(LllOO~
Insidedia., d, in 6.065 4.026
d5 8,206 1,058 I:l.P = • ' ...•.•.. . . '
I:l.P'~ 0.19(172.5/100) = 0.:33 psi at normal flow
Suction-Line-We fine the loss in the suction line by I:l.P = 0.33(250/275)2 ::::0.4 psiat maximum flow

118 . MAY 26, 1:97~/CHEMICA'L ENGINEERING

 To fin4 the pressure at the suction nozzle, we calculate
the static-head pressure: (14)(64.87)/144 = 6.3 psi, and
add this to the vessel pressure of 13 psito get 19.3 psi.
Since the pipe-friction loss ·atnormal.flow is 0.33 psi,
the pressure at the suction nozzle becomes 19.3 -'-
0.33 = 18.97 psi.. At maximum fiow, the pressure at the
suctioQ nozzle is 19.3 -'-0.4, or 18.9 psi.
Discharge-Line~We now perform similar computa-
tions to find the loss in the discharge line. Therefore, for
the discharge line;<
NRe = sO.6c250/4.026)(64.117jCl.6) = 340,000
The friction faethr,/. for this Reynolds number is
0.0178· from charts in· Part 1 of this series. We now use
Fig. 4 to find the unit loss, I:1P100' as 1.32 psi for totally
turblllent conditions at the normal flow of 250 gpm. Since
the fiow for this Reynolds number is in the trallsitional
region (see Part I of this series, Chern. Eng.,I>ec. 23,
1974, p. 65), we must correct the unitlQss as follows:
t.P1OO = 1.32(1.04)(0.0178/0.0165) = l.48 psi/loo ft.
We then find the equivalent length for the discharge
and its fittings from datain Part 2 of this series:
Pipe length;:.. ; 15Mt
20 Short-radius ..•. 210 ft
4 Gate valves.
'I Reducer. .
i8 ft
. 3 ft
2 Exits . . . . ! .'; .;... .... .•. .•. .......•..........• .... . .... 40 ft
1 Inlet .. , . . . . . . . • . . . . . . . ,.:;:.:..... . 10ft
Total equivalent length, £; .. >;:.; . . . . . • 437 ft
For this defiection, we can use a 100- or 125-in-long
manometer. The orifice I:1Po will be:
t.P.= 6.73(62.37)/144= 2.92 psi
With (3 = 0.7, the permanent loss will be 52% of the
orifice pressure differential. *
APo(loss) = 0.52(2.92) = 1.52 psi
Line 4: Friction loss in the discharge (and suction) line
has been previously computed as 6.47 psi. Line 5: Pres-
sure drop through the exchanger (and other equipment)
can be obtained from the manufacturers. Line 6 is the
sum of Lines 3 to 5 at the normal flowrate.. For a 10%
greater fiow and a pump safety factor of 1.1, resistance
of the discharge line will increase by (1.1)2. Line 7 is
the subtotal of Lines I, 2 and 6 at normal flow and at
maximum fiow.
At this point, we. will continue the calclllations at the
maximum fiowrate for reasons that will become evident.
Line 8: For the control valve to operate in an optimum
.. range at normal flow, we usually consider the valve plug
C .in afully open position at maximum flow. This also gives
a minimum pressure drop through the control valve t . A
4-in single-seat control valve has a valve coefficientt
Cv = 124. And, withCvc/Cv = 1:
liP -[
(min) -
Q
(Cvc/Cv)Cv J
"fS
!J.P _[~"f
(min) - 1 X 124 JI.04 = 5.12 psi

Hence, the overall loss for theliIle an4its fittings Line 9 is the required discharge pressure, including
at th~··normal flow of 250 gpm b~comes: control-valve I:1P at maximum flow. Suction-nozzle pres-
tFor det~i1s, see Part 5 of this series, Chern. Eng.• Apr. 14, 1975, p. 89.
t.P= AP1OO(L/IOO)
AP =1.48(437/100) =6.47 psi

liP = 6.47(275/250)2 =7.83 psi

A detailed, specific and systematic procedure is shown
in Table I for calculating the total head on the pump when
it operates at a normal fiowrate and at the maximum
flowrate.
For the calcmations presente4in Table I, the following
steps are recommended: ..
Lines 1 to 6 can be worked out simultaneously for
normal and maximum. flow. Lines land 2: Discharge-
vessel presstireand discharge static head do not change "5. C), b
with alternative flow capacities. Lines 3, 4 and 5: Orifice 50.40
I:1P, pipe-friction loss, and equipment-friction loss in- + 5.'2 c
crease with capacity. Hence: Discharge pressure ........•.... ( : + 58.34 55.51-
AP_=: (Pl4mpSafety Factor?APlIOrmal Suction·nozzle pressure j I 97 a. - '8."
Pump differential pressure ......•.... '1 39·37
1 36.6t
Requiredtotalhead,(144xAPI/p..... 87.'1- eft----- a'.3 ft
.Total head from head-capacity curve. . • . ..2L ft
Total-head safety margin. .. •.•• .. . 10.7 ft
.aOther equipment resistance...
h",= [O.l76Qv'S/(dlfJ~C)]~ bPump safetV factor,s.f." 1.l.
·With C..,IC. = 1: .
h",= {0.176(250)VT.04/(l6.21 X 0.339)]2 dWith Cve/C. = 0.5 to 0.8
h", = 80.7 in, or 6.73 ft eAHlnormal flow) = AH (maximum flow)" J.:.E.:!§.
dl.3)( '.075 "87.4

119
sure has been previously computed. By deducting the
suction·inlet pressure from the required discharge pres-
sure, we obtain the pump's differential pressure at maxi-
mum flow (Line 11). This is conyerted to the equivalent
head (Line 12) at maximum flow by using the previously
determined value of 36.62 psi from Table I:
144(~P) = 144(36.62) = 81 3f
p 64.87 . t
Let us now summarize some of these results. The
pressure needed at the pump-discharge nozzle to over~
come backpressure in the discharge line isthe sum
(Line 9 in Table I) of actual pressure in the discharge
vessel, static-head lift up to the terminating nozzle (or
liqUid .level in discharge drum), control-valve D.P, and
total discharge-pipe and equipment resistances. Pump
differential pressure (Line 11) equals discharge pressure
(Line 9) minus suctiori-nozzleptessure (Line 10). . oversized small motors in a plant can add to substantial
We can now estimate the total head at normal flowrate.
Total head will increase by an amount ranging from 0.5
to 1 of the percentage decrease in capacity. In this ex-
ample, there is a 10% decrease incapacity. Hence, for'
a single-impeller pump, we will assume an increase in
the total head of about 7.5% (i.e;, 0.75 of 10%). The
computed value is on Linel2 for the normal flow. Cal-
culated values for the total head for this example are
shown in Fig. 1b.
Suction-nozzle pressure at normal flow is on Line 10.
. Line 9 = Line 10 + Lind I;
The available pressure differential at normal flow for
control-valve sizing (Line 8) equals discharge pressure
(Line 9) minus the line backpressure without the control
valve (Line 7). This D.P should give a control~valve co-
efficient falling within' the recommended ranges of
Cve/Cv = 0.5 to 0.8 for equal-percentage contoured
plugs:
eve = QVSi....rs:P= 250(Vl.04)tvlO.71) =77.9
For the selected 4-incontrol valve, CvclCv =77.9/124,
or 0.63, which is acceptable.
For a normal flow of 250 gpm and 87.4ft total head
on the one hand, and a maximum flow of 275 gpm and
81;3 ft on the other, we can now select the pump, as shown
in Fig. I; Impeller diameter for the selected pump is
10 in, and a standard motor of 10 bhp is required. The
motor will work with abetter. than 65% efficiency.
The calculated, total-head points fall between the 9-
and lo'"-in impellers. The pumpWill operate at 95-ft total
head at 250 gpm, and at 92-ft at 275gpm. The extra
head (7.6 and 10.7 ft, respectively, here) provides a safety
margin compensating for inaccuracies in the' assessment
of the flow-properties and line data. These additional
pressure differentials can be absorbed' by the control
valve. Or, the block valve in the discharge line can be
slightly closed to bring the operating point up to the
head-capacity curve. Also, the motor will be able to drive
the pump when the liquid is colder and specific gravities
are greater than at operating conditions.
If a pump has not been selected and the head-capacity
curve is not available, a safety margin of 5 to 15% can
be estimated and added to the required total head of
Line 12.
120
-r,~~':~'r;,
"~';ft:-,;';
As thci data in Fig. Ib sho~.se~eralsizeso it1lpellers.;
can be placed in one pump case. The.cost difference' .....
between impeller sizes is negligible. MotOr sizes are usu-: '.' '.
ally well determined. A difference in the cost of the pump' .
and motor occurs for pumps falling in adjacent envelopes" ..
of the composite rating chat!. In some bordemne cases; '.,
it may be more economicalJo. redesign.the'discharge .•..
piping for lower pressure drop rtther,Jhai}to invest i~'
a larger pump and motor.'.' '.: •.. . ';'~( .' . .~ ... :. •.....•. , :
For economy in utility cost,the.primp shoukl work at
its highest efficiency.' High putnpefficiencyresultsin .
.minimum horsepower input, and' lilinimum wear. and' ,
maintenance. High-efficienty pumps . last longer, are . •..•
quieter and vibrate less than low-efficiency ones{21.. '·
Small pumps should not· be oversized. 'the total of
waste in energy usage. . . '.' .' .' .' . ' , ,
For pipe diameters above 12 in, more than one Size
may be selected initially because capacity increments in
large-size pipe are very close.. Piping costs,. of course,
increase with diameter, while utility costs decrease.be-
cause of smaller pipe .and componentsresista11ces~The.,
best size can be determined by adding the totalcost of'
utilities over the period of capital payout ;io~ theccist of.
the mechanical and electrical installation:. The. lowest
total cost calculated for a 2-, 5~ or 10-:yr '~mdrtization • •
will give the most economical design. ", .< '; .
A detailed investigation for the' most'.econolillcat pipe
size is justified if line sizes are large, pipe ~nfigurations
are long or complicated, or if the pipjrig material is
expensive. Pipe friction must contribute a major portion
of the discharge pressure-otherwise, there will be little
difference in total heads between alternative designs.
Actual vessel pressures and static liqui4 heights usually
cannot be altered. ' . c : ' '. ' ' ' ' ' . , .'
For reciprocating pumps, the avaiIableNPSH, pump
differential pressure, suction-line and discharge-line re-
si'stances cannot be calculated' in the same way as for
centrifugals. Because of pulsating flow, the minimum-
pressure levels should not fall below the vapor pressure
when saturated liquid is pumped. For identicalflowrates,
pressure losses in suction and discharge lines of recipro-
cating pumps are greater than in those of centrifugal
. pumps. These principles have beenadequately discussed
by Hattiangadi [3]. For information on power ratings,
installation and operation ofrecipr9cating pumps, con-
sult the "Hydraulic Institute Standards" 14]. The Stand-
ards [4] also contain information on electric-~otor-
driven and steam-driven reciprocating pumps. .
The next article in this series will appear in the issue
of June 23, 1975,and will reviewpiping design for two-
phase (i.e., vapor-!iquid) flow: # . .
References
L ."Hydniulic Institute Stand~rds," 12th ed,p. 81; Hydraulic Institute,
New York, 1969. .
2. Marischen; J. P.,,,Cri\ical Centtifugal Pump Iriformation," Ampco
Metal Inc., Milwaukee, WI 53201.' .... .... .,. ..
3.' Hattiangadi; U. S.;Specifying CenttifugalandReciproeating Pumps,
Chern. Eng., Feb. 23, 1970,pp.lOI.c108, ....
4. "Hydraulic InstituteStimdards," 12th ed. pp.165-166, 181:"182,204-
205, Hydraulic Institute,New York;'1969.';···· c.